C08F222/00—Copolymers of compounds having one or more unsaturated aliphatic radicals, each having only one carbon-to-carbon double bond, and at least one being terminated by a carboxyl radical and containing at least one other carboxyl radical in the molecule; Salts, anhydrides, esters, amides, imides, or nitriles thereof

G02B1/00—Optical elements characterised by the material of which they are made

G02B1/04—Optical elements characterised by the material of which they are made made of organic materials, e.g. plastics

G02B1/041—Lenses

Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS

Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC

Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION

Y10T428/00—Stock material or miscellaneous articles

Y10T428/31504—Composite [nonstructural laminate]

Y10T428/31855—Of addition polymer from unsaturated monomers

Abstract

The present invention relates to a new polymer compositions for use in the manufacture of ophthalmic lenses, to their use in ophthalmology and to apparatus using these lenses, such as eyepieces and film/video camera optics.

The present invention relates to new polymer compositions for use in the manufacture of ophthalmic lenses, to their use in ophthalmology and to apparatus using these lenses, such as eyepieces and film/video camera optics.

Ophthalmic plastics obtained from acrylic bisphenol A derivatives are in general too yellow for use.

The use of additives which reduce yellowness is well know, but usually at the cost of the degree of polymerisation and thermomechanical properties.

Ophthalmic lenses may be produced in their final shape by casting polymerisable compositions between two moulds having the required surface geometries, then polymerising. A lens is then obtained with its two surfaces in their final state.

In order to reduce the need for large stocks of ophthalmic lenses, semi-finished lenses are often made which have one moulded side only in its final geometry, the second side being finished when required.

Finishing the second side raises the temperature of the semi-finished lens and it is therefore vital that the polymer constituting the lens is sufficiently rigid and non-deformable at the temperature attained. The polymer must therefore have good thermomechanical properties.

The applicant has discovered that it is possible to produce polymers for the manufacture of ophthalmic lenses in accordance with the invention which have good thermomechanical properties and a low yellow index making them particularly suitable for use in the manufacture of ophthalmic lenses from a copolymerisable composition comprising at least one monomer having formula ##STR1## and at least one monomer derived from allyl alcohol. This composition constitutes an object of the invention.

Monomers having formula I are known and some of their derivatives have already been recommended for use in ophthalmology (GB-A-1 514 810, FR-A-2 431 511). In the latter document, monomers having formula I are used with monomers which are copolymerisable by a radical mechanism, wherein the homopolymer has an index greater than or equal to 1.55 to produce high index lenses.

Polymers produced from a monomer having formula I and the copolymers described in FR-A-2 431 511 are, however, too yellow to be usable in ophthalmology without modification.

The invention consists in polymers constituted by units derived from monomers having formula I and allyl alcohol derivatives.

The invention further consists in polymerisable compositions comprising monomers having formula I and allyl alcohol derivatives.

The invention further consists in ophthalmic lenses produced from these polymers, their use in ophthalmology and apparatus containing these optics.

Further objects of the invention will become apparent from the following description and examples.

A polymer composition in accordance with the invention is characterized in that it is obtained by polymerisation of a polymerisable composition comprising:

at least 50% and preferably 70 to 100% by weight of a monomer or mixture having formula I ##STR2## wherein R1 and R2 independently of each other may represent hydrogen or a low C1 -C6 alkyl radical, X represents ##STR3## m and n are integers and the sum m+n being between 0 and 10, and

0 to 50% by weight of one or more mono- or polyfunctional vinyl, acrylic or methacrylic comonomers (II);

(B) a component B in a proportion of 0.05 to 15%, preferably 0.1 to 15% and most preferably 0.1 to 5% by weight with respect to the weight of monomers (I) and (II) of at least one monomer (III) comprising an ethylenic unsaturation which does not form part of an aromatic ring and containing in position α of this unsaturation, a carbon atom carrying a free hydroxy group and preferably linked to at least one hydrogen atom.

The ethylenic unsaturated monomers (III) used according to the invention are preferentially selected from the monomers having formula (IV). ##STR4## wherein R3 and R4 represent hydrogen or one of the groups R3 and R4 represent hydrogen while the other forms with group R7 a C5 -C10 ring which may be substituted by one or more linear or branched C1 -C4 alkyl groups or one or more C2 -C4 alkylene groups; or one of groups R3 and R4 may represent hydrogen while the other represents an aliphatic C1 -C6 alkyl group, a cyclic C4 -C16 hydrocarbon group or an aromatic C6 -C16 hydrocarbon group;

R5, R6 and R7, independently of each other, represent hydrogen or a C1 -C6 alkyl group which may be substituted by one or more OH groups and wherein the chain may be interrupted by one or more ether, ester or ketone groups; an aromatic C6 -C16 hydrocarbon group or a cyclic C4 -C16 hydrocarbon group;

R7 may form with one of the groups R3 or R4 and C5 -C10 ring which may be substituted by one or more linear or branched C1 -C4 alkyl groups or one or more C2 -C4 alkylene groups;

R5 and R6 may form a C5 -C10 ring which may be substituted by one or more C1 -C4 alkyl groups or C2 -C4 alkylene groups;

two or more of the carbon atoms of the C5 -C10 ring formed with R3 or R4 and R7 or with R5 and R6, may be bonded by a hydrocarbon bridge.

In accordance with the invention, the C1 -C6 alkyl group preferably represents a methyl or ethyl group.

Particularly preferred monomers having formula I are those wherein R1 denotes CH3 and R2 denotes hydrogen and X represents ##STR5## and m+n is a whole number between 2 and 7. Particularly preferred monomers having formula III are those wherein R3 and R4 represent hydrogen, R5 represents methyl, R6 represents hydrogen or methyl and R7 represents hydrogen, methyl, ethyl or CH2 OH.

Preferred polymers are those wherein the monomer having formula I is 2,2-bis (4-methacroyloxydiethoxyphenyl)propane.

Monomers having formula II may be aromatic or non-aromatic.

The following monofunctional aromatic compounds may be cited: phenyl(meth)acrylate, benzyl(meth)acrylate, phenoxyethyl(meth)acrylate, styrene.

The following non aromatic compounds are preferred: a monofunctional alkyl(meth)acrylate such as methyl(meth)acrylate, ethyl(meth)acrylate, butyl(meth)acrylate or isobutyl(meth)acrylate or difunctional derivatives such as butanedioldi(meth)acrylate, or trifunctional derivatives such as trimethylolpropane tri(meth)acrylate.

The polymerisable compositions and the polymer compositions in accordance with the present invention may further include usual anticoloring agents such as phosphinic compounds, for example triphenylphosphine. The amounts of anticoloring agents used in the present compositions are the usual amounts, preferably 0.01 to 0.5% by weight.

Polymerisation is effected in a known manner using an initial mixture containing the various monomers of the polymerisable composition, the polymerisation reaction being catalysable using catalysts such as benzoyl peroxide, cyclohexyl peroxydicarbonate, diisopropyl peroxydicarbonate or 2,2'-azo-bis isobutyronitrile. The catalysts are used in quantities sufficient to initiate or maintain polymerisation and are normally present in proportions of between 0.001 and 1% by weight with respect to the total weight of the polymerisable composition.

Ophthalmic lenses are prepared by introducing the desired composition containing the various monomers described above into an apparatus constituted by a glass two-part mould and initiating a thermal polymerisation cycle of 10 to 20 hours duration at about 45° C. to 90° C., preferably about 50° to 85° C. It is also possible to polymerise photochemically or by induction heating using electromagnetic radiation, such as microwaves (2 450 MHz or 915 MHz) or high-frequency radiation (3.56 MHz; 27.12 MHz or 40.68 MHz).

Polymerisation by induction heating is normally completed in a period of less than one hour.

The polymer lens thus produced is then annealed for a period and at a temperature sufficient to eliminate residual stresses in the lens. The temperature is generally between 100° and 120° C. and annealing is carried out for about 1 to 5 hours.

It is also possible to effect polymerisation using moulds with one surface conforming to the final lens geometry and a second surface which does not conform to the final lens surface geometry but produces a second lens surface which can be finished when required.

The invention also consists in a polymerisable composition as defined above when used in the preparation of polymer compositions.

The polymerisable compositions and the polymer compositions thus obtained, particularly following moulding, may be used to produce ophthalmic components such as ophthalmic lenses, spectacle or eyepiece lenses, and the optics of various devices including cameras, film/video cameras and microscopes for example.

In particular, these compositions are especially suitable for producing photochromic substrates and items such as photochromic ophthalmic lenses. Thus, the invention also concerns photochromic substrates made of a polymer composition as described above which further includes one or more photochromic compounds.

Preferably, the photochromic compound is incorporated into a substrate made of the moulded polymer composition up to a depth of 100 to 150 μm from a surface of the substrate. Incorporation of the photochromic compound is preferably effected by a thermal transfer process.

Such a thermal transfer process is well-known and is disclosed in U.S. Pat. Nos. 4,286,957 and 4,880,667.

Any usual photochromic compound useful in the optical field may be used for making the photochromic substrates and items according to the present invention, the prefered photochromic compounds being of the chromene type.

The yellow index is determined spectroscopically and visually. A standardised method is used to determine the yellow index by the spectroscopic method (ASTM D-1325-63). The yellow index is defined as follows: ##EQU1## where X, Y, Z are trichromatic coordinates of the sample measured using a UV-visible spectrophotometer scanning the spectrum from 380 to 780 nanometers. Yi is determined before and/or after annealing.

The visual method uses four standard glass samples containing increasing quantities of yellow dye to establish a range of yellows. Samples are classified according to their respective levels of yellow.

The degree of polymerisation is determined by measurements of the near infrared peak for the methacrylic group double bond by observing the area of the 6160 cm-1 peak which corresponds to the first harmonic of the terminal methylene group CH bond vibration. The degree of polymerisation is given by: ##EQU2##

Thermomechanical properties are determined using a three point bending TMA apparatus. Lens rigidity is characterized by the high temperature moduli in the rubber-like region.

The following examples illustrate but do not limit the scope of the invention.

For examples 1 to 6, an initial mixture was prepared by homogenisation for one hour of specific amounts of tetraethoxy bisphenol A dimethacrylate sold by AKZO under the trade name Diacryl 121 and, if required, methacrylic monomers (ethyl methacrylate, butanediol dimethacrylate). Cyclohexyl peroxydicarbonate was used as catalyst in a proportion of 0.5% with respect to the total formulation.

Allyl alcohol derivatives having formula IV were introduced in the proportions indicated below just before casting into an apparatus constituted by two two-pat glass moulds and an EVA gasket. The assembly then underwent an 18 hour thermal cycle starting from a temperature of 48° C. and arriving at 85° C. after 16 hours.

The polymerised articles thus produced were annealed for three hours at 110° C. before measurement of their properties.

Except when specified, the final articles have a thickness of 2 mm.

EXAMPLE 1

A mixture as described above was prepared by homogenising tetraethoxy bis-phenol A dimethacrylate sold by AKZO under the trade name Diacryl 121 and ethyl methacrylate in proportions of 92 parts Diacryl 121 to 8 parts ethyl methacrylate with stirring. This mixture was catalysed with 0.5% by weight of cyclohexyl peroxydicarbonate (CHPC). A compound having the following formula IV was then introduced into the resulting composition: ##STR6## wherein R3, R4, R5 and R6 have the meanings shown in the table below.

A polymerisable composition was used comprising 85 parts by weight of Diacryl D 121 and 15 parts by weight of 1,4-butanediol dimethacrylate which had been homogenized as described above. 0.5% by weight of cyclohexyl peroxydicarbonate was used as catalyst. The following results were obtained:

A polymerisable composition was prepared using tetraethoxy bis-phenol A dimethacrylate sold by AKZO under the trade name Diacryl 121. This monomer was mixed with 0.5% by weight of cyclohexyl peroxydicarbonate. The compounds shown in Table IV were then introduced as additives to give the results indicated below.

•level 0: corresponds to the colour of Orma without any addition of yellow dye (Orma is the trade name for a polymer material obtained from diethyleneglycol bis (allyl carbonate) manufactured by ESSILOR and used as a reference material;

•level 1: Orma+0.0025% of yellow dye Neozapon 157;

•level 2: Orma+0.01% of yellow dye Neozapon 157;

•level 3: Orma+0.025% of yellow dye Neozapon 157.

The levels were determined in accordance with the following table ##STR7##

EXAMPLE 6

A polymerisable composition was prepared using tetraethoxy bis-phenol A dimethacrylate sold by AKZO under the trade name Diacryl 121.

The compounds shown in Table VII were then introduced as additives in the proportions indicated. To this mixture, a photoinitiator was added in a proportion of about 0.1%.

The said photoinitiator is CGI 1700 of CIBA-GEIGY which is a mixture containing the following compounds: ##STR8## in a ratio B/A=75/25.

After casting in a mould, the mixture was irradiated by a mercury lamps during 5 minutes. An annealing was then carried out during one hour at 120° C. The final article has a thickness of 2 mm.

The additives shown in Table VII are corresponding to the formula (IV) ##STR9##

Ophthalmic substrates of 12 mm thickness were prepared from different compositions comprising a basic monomer mixture consisting of about 55% by weight of diethoxydimethacrylate bisphenol A and about 45% by weight of dilution monomers consisting essentially of mono and dimethacrylate derivatives. This mixture of monomers will be designated throughout the remaining part of the description as the "basic monomer mixture".

The above results show that 3-methyl 2-butene 1-ol acts upon the yellow level both before and after annealing, even at low concentration.

On the other hand, the incorporation of triphenylphosphine further limits yellowing during the annealing.

PREPARATION OF PHOTOCHROMIC SUBSTRATES

The substrates obtained from compositions of comparative example Ref. 1 and of examples 7, 8, 9, 11 and 12 were subjected to a photochromatization by thermal transfer.

The thermal transfer process is well-known and is disclosed in U.S. Pat. Nos. 4,286,395 and 4,880,667.

To this end, a cellulose acetobutyrate base photochromic varnish including a chromene type photochromic compound was prepared.

Each of the substrates were coated with the varnish and the coated substrates were placed in an oven at 135° C. for 5 hours.

Thereafter, the substrates were withdrawn and cooled to ambient temperature in air. The varnish films were peeled off. Penetration depths of the photochromic compounds into the substrates were determined to be 100-150 μm.

The kinetic of the photochromic compound incorporated into the substrates was then measured at a temperature of 29° C.

The substrates were irradiated for 8 minutes using a lamp (solar simulator) providing a visible light of 65.6±5 klux and a UV light of 8.98±5 W/cm2.

Following this 8 minutes irradiation, optical density of each substrate was measured at the wavelength corresponding to the maximum of absorption in visible light of the photochromic compound incorporated into the substrate. This measured optical density is referred to as the maximal optical density D08.

After shut off the lamp, optical density measurement was pursued and for each substrate the time after which the optical density reached the value ##EQU3##

where DO0 is the substrate optical density at the non-activated initial state, was noted. This time (t1/2), in seconds, is referred to as the bleach rate.

The results show that the photochromic kinetic of the substrates of Examples 13 and 14 is greatly improved compared with reference substrate Ref. 1.

Claims (32)

What is claimed is:

1. A polymer composition obtained by polymerisation of a composition comprising:

a component A comprising:

•at least 50% by weight of a monomer or mixture of monomers having formula I: ##STR11## wherein R1 and R2, which may be identical or different, represent hydrogen of C1 -C6 alkyl, X represents: ##STR12## m and n are integers and m+n is between 0 and 10;

0to 50% by weight of one or more mono- or polyfunctional vinyl, acrylic or methacrylic comonomers (II); and

a component B comprising:

•in a proportion of 0.05 to 15% by weight with respect to the weight of components (I) and (II), at least one monomer (III) comprising an ethylenic unsaturation which does not form part of an aromatic ring and containing in position α of this unsaturation, a carbon atom carrying a free hydroxy group.

2. The polymer composition of claim 1, wherein the monomer (III) contains in position α of the unsaturation, a carbon atom carrying a free hydroxy group and being linked to at least one hydrogen atom.

3. The polymer composition of claim 1, wherein the monomer (III) has formula (IV): ##STR13## wherein R3 and R4 represent hydrogen or one of the groups R3 and R4 represent hydrogen while the other forms with group R7 a C5 -C10 ring which may be substituted by one or more linear or branched C1 -C4 alkyl groups or one or more C2 -C4 alkylene groups; or one of groups R3 and R4 may represent hydrogen while the other represents an aliphatic C1 -C6 alkyl group, a cyclic C4 -C16 hydrocarbon group or a C6 -C16 aromatic hydrocarbon group;

R5, R6 and R7, independently of each other, represent hydrogen or a C1 -C6 alkyl group which may be substituted by one or more OH groups and wherein the chain may be interrupted by one or more ether, ester or ketone groups; an aromatic C6 -C16 hydrocarbon group or a cyclic C4 -C16 hydrocarbon group;

R7 may form with one of the groups R3 or R4 and C5 -C10 ring which may be substituted by one or more linear or branched C1 -C4 alkyl groups or one or more C2 -C4 alkylene groups;

R5 and R6 may form a C5 -C10 ring which may be substituted by one or more C1 -C4 alkyl groups or C2 -C4 alkylene groups;

two or more of the carbon atoms of the C5 -C10 ring formed with R3 or R4 and R7 or with R5 and R6, may be bonded by a hydrocarbon bridge.

6. The polymer composition of claim 1, wherein the compound having formula I is used in proportions between 70 and 100% by weight with respect to the weight of component A.

7. The polymer composition of claim 1, wherein R1 represents CH3 and R2 represents H and X represents ##STR14## m and n are integers and m+n is a whole number between 2 and 7.

8. The polymer composition of claim 1, wherein the monomers having formula (II) are selected from the group consisting of phenyl(meth)acrylate, benzyl(meth)acrylate, phenoxyethyl(meth)acrylate and styrene or from the non-aromatic compounds which are selected from the group consisting of methyl(meth)acrylate, ethyl(meth)acrylate, butyl(meth)acrylate or isobutyl(meth)acrylate, butanedioldi(meth)acrylate, and trimethylolpropane tri(meth)acrylate.

9. The polymer composition of claim 1, wherein the compound having formula I is 2,2-bis (4-methacroyl oxdiethoxyphenyl)propane.

12. The polymer composition of claim 1, which further comprises a phosphinic anticoloring agent.

13. The polymerisable composition of claim 12, wherein the monomer (III) has formula (IV): ##STR15## wherein R3 and R4 represent hydrogen or one of the groups R3 and R4 represent hydrogen while the other forms with group R7 a C5 -C10 ring which may be substituted by one or more linear or branched C1 -C4 alkyl groups or one or more C2 -C4 alkylene groups; or one of groups R3 and R4 may represent hydrogen while the other represents an aliphatic C1 -C6 alkyl group, a cyclic C4 -C16 hydrocarbon group or a C6 -C16 aromatic hydrocarbon group;

R5, R6 and R7, independently of each other, represent hydrogen or a C1 -C6 alkyl group which may be substituted by one or more OH groups and wherein the chain may be interrupted by one or more ether, ester or ketone groups; an aromatic C6 -C16 hydrocarbon group or a cyclic C4 -C16 hydrocarbon group;

R7 may form with one of the groups R3 or R4 and C5 -C10 ring which may be substituted by one or more linear or branched C1 -C4 alkyl groups or one or more C2 -C4 alkylene groups;

R5 and R6 may form a C5 -C10 ring which may be substituted by one or more C1 -C4 alkyl groups or C2 -C4 alkylene groups; two or more of the carbon atoms of the C5 -C10 ring formed with R3 or

15. A photochromic substrate made of a polymer composition according to claim 14, wherein at least one photochromic compound is incorporated within the substrate.

16. The photochromic substrate of claim 15, wherein the photochromic compound is incorporated within the substrate to a depth of 100 to 150 μm from a surface of the substrate.

17. A method of preparing a polymer composition as defined in claim 1 comprising:

mixing one or more monomers having formula I and II and 0.05 to 15% by weight with respect to the weight of monomers having formula I and II of at least one monomer (III), and polymerising the mixture.

18. The method of claim 17, wherein the monomer (III) has formula (IV): ##STR16## wherein R3 and R4 represent hydrogen or one of the groups R3 and R4 represent hydrogen while the other forms with group R7 a C5 -C10 ring which may be substituted by one or more linear or branched C1 -C4 alkyl groups or one or more C2 -C4 alkylene groups; or one of groups R3 and R4 may represent hydrogen while the other represents an aliphatic C1 -C6 alkyl group, a cyclic C4 -C16 hydrocarbon group or a C6 -C16 aromatic hydrocarbon group;

R5, R6 and R7, independently of each other, represent hydrogen or a C1 -C6 alkyl group which may be substituted by one or more OH groups and wherein the chain may be interrupted by one or more ether, ester or ketone groups; an aromatic C6 -C16 hydrocarbon group or a cyclic C4 -C16 hydrocarbon group;

R7 may form with one of the groups R3 or R4 and C5 -C10 ring which may be substituted by one or more linear or branched C1 -C4 alkyl groups or one or more C2 -C4 alkylene groups;

R5 and R6 may form a C5 -C10 ring which may be substituted by one or more C1 -C4 alkyl groups or C2 -C4 alkylene groups;

two or more of the carbon atoms of the C5 -C10 ring formed with R3 or R4 and R7 or with R5 and R6, may be bonded by a hydrocarbon bridge.

19. The method of claim 17, wherein the polymerisation is carried out photochemically.

20. The method of claim 17, wherein the polymerisation is carried out by induction heating.

21. An ophthalmic lens made of a polymer composition obtained by the method according to claim 17.

22. An ophthalmic lens made from a polymer composition according to claim 1.

23. A lens assembly characterized in that it comprises at least one lens as defined in claim 22.

24. A photochromic substrate made of a polymer composition according to claim 1, wherein at least one photochromic compound is incorporated within the substrate.

25. The photochromic substrate of claim 24, wherein the photochromic compound is incorporated within the substrate to a depth of 100 to 150 μm from a surface of the substrate.

26. A polymiserable composition comprising at least 50% by weight of a monomer or mixture of monomers having formula I: ##STR17## wherein R1 and R2, which may be identical or different, represent hydrogen or C1 -C6 alkyl, X represents: ##STR18## m and n are integers and m+n is between 0 and 10;

0to 50% by weight of one or more mono- or polyfunctional vinyl, acrylic or methacrylic comonomers (II); and

a component B comprising:

•in a proportion of 0.05 to 15% by weight with respect to the weight of components (I) and (II), at least one monomer (III) comprising an ethylenic unsaturation which does not form part of an aromatic ring and containing in position α of this unsaturation, a carbon atom carrying a free hydroxy group.

29. The polymerisable composition of claim 26, wherein the monomer (III) contains in position α of the unsaturation, a carbon atom carrying a free hydroxy group and linked to at least one hydrogen atom.

30. The polymerisable composition of claim 26, further comprising a phosphinic anticoloring agent.

32. A method of preparing a finished or semi-finished lens comprising casting a polymerisable composition according to claim 26, between two moulds having the required surface geometries and polymerising the composition.

Composition of aromatic poly(allylcarbonate), styrene materials, and crosslinker containing three or more ethylenically unsaturated groups for producing polymer of high refractive index and low yellowness